Dunkirk WPSB SERIES II Installation & Operation Manual
- Category
- Water heaters & boilers
- Type
- Installation & Operation Manual
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DUNKIRK BOILERS
DUNKIRK, NEW YORK 14084 AREA CODE 716 366-5500
MEMBER: The Hydronics Institute
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Warning: Improper installation, adjustment, alteration, service or maintenance can cause injury or
property damage. Refer to this manual. For assistance or additional information consult a qualified
installer, service agency or the gas supplier
Gas-Fired
Hot-Water
Boilers
These Gas-Fired Water Boilers are low pressure, sectional
cast iron boilers Designed Certified by C.S.A. (Canadian
Standards Association) for use with Natural and Propane
Gases. They are constructed and hydrostatically tested for a
maximum working pressure of 50 psi (pounds per square
inch) in accordance with A.S.M.E. (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code
Section IV Standards for cast iron heating boilers.
WPSB
SERIES
MODEL WPVSB
Continuous Pilot
MODEL WPSB
Electronic
Intermittent Ignition
2
Boiler Ratings and Capacities
The Ratings marked Net 1=B=R Ratings indicate the amount
of remaining heat input that can be used to heat the radiation or
terminal units. The Net 1=B=R Ratings shown are based on an
allowance of 1.15 in accordance with the factors shown on the
1=B=R Standard as published by The Hydronics Institute.
Selection of boiler size should be based upon Net 1=B=R
Rating being equal to or greater than the calculated heat loss
of the building.
The manufacturer should be consulted before selecting a boiler
for installations having unusual piping and pickup
requirements.
These boilers must stand on a non-combustible floor. If
installed on a combustible floor, use Combustible Floor Base
Number 42135-1 or 146-14-031 (3-6 section boilers) or 42135-
2 or 146-14-032 (7-9 section boilers).
BOILERS FOR USE AT HIGH ALTITUDE
This boiler is factory equipped for use at altitudes of 0-2,000
feet above sea level. For use at altitudes above 2,000 feet
above sea level, the input ratings are reduced by a change in
main burner orifice size.
For altitudes above 2,000 feet above sea level, input ratings
should be reduced at the rate of 4% for each 1,000 feet
above sea level. Consult the National Fuel Gas Code
(NFPA54/ANSI Z223.1-latest edition), or the manufacturer
for correct orifice sizing information. High altitude orifices
are available from the boiler manufacturer.
* MBH = 1,000 Btuh = British Thermal Unit Per Hour
**Add 5½ to height for vent Damper.
For altitudes above 2,000 ft. rating should be reduced at the rate of 4% for each 1,000 ft. above sea level.
Heating Capacity is based on D.O.E. (Department of Energy) test procedure.
GAS-FIRED HOT-WATER BOILERS
FIG. 1
Before You Start
KEEP BOILER AREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS,
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS
Check to be sure you have the right size boiler before starting
the installation. See rating and capacity table on previous
page. Also be sure the new boiler is or the type of gas you
are using. Check the rating plate on the right side of the boiler.
You must see that the boiler is supplied with the correct type
of gas, fresh air for combustion, and a suitable electrical
supply. Also, the boiler must be connected to a suitable
venting system and an adequate piping system. Finally, a
thermostat, properly located, is needed for control of the
heating system. If you have any doubts as to the various
requirements, check with local authorities and obtain
professional help where needed. Take the time to complete
all of the steps for SAFE and PROPER operation of the
heating system.
If this boiler is installed in a building under construction,
special care must be taken to insure a clean combustion
air supply during the construction process. Airborne
particulates such as from drywall dust and from fiberglass
insulation can clog the burner ports and cause incomplete
combustion and sooting.
Where required by the authority having jurisdiction, the
installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for
Automatically Fired Boilers, No. CSD-1.
The installation must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI Z223.1-
latest revision.
Locating the Boiler
1. Select level location as centralized with piping system,
and as near chimney, as possible.
2. Place crated boiler at selected location, remove crate
by pulling crate sides from top and bottom boards.
Combustible floors: When boiler is to be installed on a
combustible floor, a Special Base Plate must be used -
146-14-031 (2-6 Section) or 146-14-032 (7-9 Section).
This boiler must not be installed on carpeting.
3. Boiler is to be level. Metal shims may be used under
base legs for final leveling.
4. Accessibility clearances must take precedence over
fire protection clearances. An 18-inch clearance
should be maintained on any side where passage is
required to access another side for cleaning, servicing,
inspection or replacement of any part that may need
attention. An 18-inch clearance is recommended on the
control side for servicing.
Figure 2 shows minimum clearances to combustible
construction. Rooms that are large in comparison with
the size of the boiler are defined as rooms having a
volume equal to or greater than 16 times the volume of
the boiler. Where the actual ceiling height of a room is
greater that 8', the volume of a room shall be figured on
the basis of a ceiling height of 8'. Determination of room
size should be based do the total volume of all gas fired
equipment installed in the room. Consult section 6.3.1
of the National Fuel Gas Code for further information,
including approved methods for reducing clearances in
large rooms.
5. Equipment shall be installed in a location in which the
facilities for ventilation permit satisfactory combustion
of gas, proper venting, and maintenance of ambient
temperature at safe limits under normal conditions of
use. Equipment shall be located so as not to interfere
FIG. 2 - MINIMUM CLEARANCE DIMENSIONS
with proper circulation of air. When normal infiltration
does not provide the necessary air, outside air shall be
introduced (See Page 4 - Fresh Air for Combustion).
6. Advise owner to keep air passages free of obstructions.
Ventilating and combustion air must enter boiler room
without restrictions.
7. The boiler shall be installed such that the automatic gas
ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation
and service (condensate trap, control replacement, etc.).
3
You must provide for enough fresh air to assure proper
combustion. The fire in the boiler uses oxygen. It must have a
continuous supply. The air in a house contains only enough
oxygen to supply the burner for a short time. Outside air must
enter the house to replace that used by the burner. Study following
examples 1 and 2 to determine your fresh air requirements.
EXAMPLE 1: Boiler Located in Unconfined Space
An unconfined space is defined as a space whose volume is
not less than 50 cubic feet per 1,000 Btu per hour of the total
input rating of all appliances installed in that space.
If your boiler is in an open area (unpartitioned basement) in a
conventional house, the air that leaks through the cracks around
doors and windows will usually be adequate to provide air for
combustion. The doors should not fit tightly. Do not caulk the
cracks around the windows.
Equipment located in buildings of unusually tight construction
shall be provided with air for combustion, ventilation, and
dilution of flue gases using the methods described in example
2B or shall be specially engineered. The authority having
jurisdiction must approve specially engineered installations.
EXAMPLE 2: Boiler Located in Confined Space
A. All Air from Inside the Building: The confined space shall
be provided with two permanent openings communicating
directly with an additional room(s) of sufficient volume so
that the combined volume of all spaces meets the criteria
for an unconfined space. The total input of all gas utilization
equipment installed in the combined space shall be
considered in making this determination. Each opening
shall have a minimum free area of one square inch per
1,000 Btu per hour of the total input rating of all gas
utilization equipment in the confined space, but not less
that 100 square inches. One opening shall be within 12
inches of the top and one within 12 inches of the bottom of
the enclosure. The minimum dimension of air openings shall
not be less than 3 inches.
B. All Air from Outdoors: The confined space shall
communicate with the outdoors in accordance with methods
1 or 2. The minimum dimension of air openings shall not
be less than 3 in. Where ducts are used, they shall be of
the same cross-sectional area as the free area of the
openings to which they connect.
1. Two permanent openings, one commencing within 12
inches of the top and one commencing within 12 inches
of the bottom, of the enclosure shall be provided. The
openings shall communicate directly, or by the ducts, with
the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
a) Where directly communicating with the outdoors or where
communicating to the outdoors through vertical ducts.
Each opening shall have a minimum free area of 1 sq.
in. per 4000 Btu per hour of total input rating of all
equipment in the enclosure. (See Figure 3B)
b) Where communicating with the outdoors through
horizontal ducts. Each opening shall have a minimum
free area of 1 sq. in. per 2000 Btu per hour of total input
rating of all equipment in the enclosure. (See Figure 38.)
WARNING
Be sure to provide enough fresh air for combustion. Enough
air insures proper combustion and assures that no hazard
will develop due to the lack of oxygen.
Fresh Air for Combustion
Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation,
of the National Fuel Gas Code, ANSI Z223.1-latest revision, or applicable provisions of the local building codes.
NOTE
If you use a fireplace or a kitchen or bathroom exhaust fan,
you should install an outside air intake. These devices will
rob the boiler and water heater of combustion air.
2. One permanent opening commencing with 12 inches of
the top of the enclosure, shall be permitted where the
equipment has clearance of at least 1 inch from the sides
and back and 6 inches from the front of the appliance.
The opening shall directly communicate with the outdoors
or shall communicate through a vertical or horizontal duct
to the outdoors or spaces (crawl or attic) that freely
communicate with the outdoor, and shall have a minimum
free area of:
a) 1 sq. inch per 3000 Btu per hour of the total input of all
equipment located in the enclosure ( See Figure 4), and
b) Not less than the sum of the areas of all vent connectors
in the confined space.
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Figure 3A - FRESH AIR DUCT CAPACITIES (Btuh)
Figure 3B - FRESH AIR DUCT CAPACITIES (Btuh)
Figure 4 - FRESH AIR DUCT CAPACITIES (Btuh)
4
Installation - System Piping
1. Place boiler in the selected location (as near chimney as
possible.) Your boiler is shipped assembled. You need only
to install the Relief Valve and a drain line to carry any water
or steam to a drain.
2. Install Relief Valve into the 3/4" pipe on the top of the boiler.
See Figure 5. Use 3/4 Pipe and an elbow (not furnished)
to carry the water or steam to a nearby drain. Do not connect
directly to a drain but leave an air gap. No shutoff of any
description shall be placed between the safety relief valve
and the boiler, or on discharge pipes between such safety
valves and the atmosphere. Installation of the safety relief
valve shall conform to the requirements of the ANSI/ASME
Boiler and Pressure Vessel Code, Section IV. The
manufacturer is not responsible for any water damage.
Install Drain Valve in lower left side of boiler as marked.
3. Connect Supply and Return Lines to boiler. The connections
may require certain additional fittings and parts, as shown
on diagram (Figs. 5 and 6).
4. This boiler is equipped with 1
1/4" supply and return
connections on both the left and right sides of the boiler.
In connecting the cold water supply to the water inlet valve,
make sure that a clean water supply is available. When the
water supply is from a well or pump, a sand strainer should
be installed at the pump.
A hot water boiler installed above radiation level must be
equipped with a low water cutoff device. A periodic inspection
is necessary, as is flushing of float type devices, per
manufacturers specific instruction.
FOR USE WITH COOLING UNITS
A. This boiler, when used in connection with chilled water
systems, must be installed so that the chilled water is piped
in parallel with the heating boiler. Appropriate valves must
be used to prevent the chilled water from entering the
heating boiler (Fig. 6).
B. When this boiler is connected to heating coils located in air
handling units where they may be exposed to refrigerated
air circulation, the piping system shall be equipped with flow
control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
LOW WATER TEMPERATURE AND LARGE
WATER CONTENT SYSTEM
Significant condensation may form in this boiler and/or the
venting system if the boiler is operated for a long period of
time with return temperatures of less than 120° F.
This condensation is corrosive and can eventually cause
severe damage to the boiler and venting system. The
minimum design return water temperature to prevent
condensation in the boiler and venting is 120°F. The minimum
high limit setting is 140°F.
1. If the boiler is to be used in a heating system where design
water temperatures below 140°F are desired (e.g. radiant
floor heating), a 4-way mixing valve or suitable alternative
is required to prevent low temperature return water from
entering the boiler. Follow the mixing valve manufacturers
instructions.
2. If the boiler is to be connected to a system having a large
water content (such as a former gravity system), install a
system bypass as shown in Figures 7 and 8.
3. If a boiler water reset control is used to operate the boiler,
the minimum reset supply water temperature setpoint
must be at least 140°F, unless a mixing valve is used as
in (1) above.
FIG. 5 - TYPICAL HOT WATER PIPING
FIG. 6 - CHILLED WATER PIPING
5
Chimney and Vent Pipe Connection
CHECK YOUR CHIMNEY
This is a very important part of your heating system. It must
be clean, the right size, properly constructed and in GOOD
CONDITION. No boiler can function properly with a bad
chimney.
CHIMNEY SIZING
Chimney sizing, and all other aspects of the vent installation
must be in accordance with Part 7 and Part 11 of the National
Fuel Gas Code, ANSI Z223 1- latest revision, and applicable
provisions of the local building codes.
This is a high efficiency boiler with a low stack temperature.
The following recommendations are in addition to the
requirements of the National Fuel Gas Code.
1. Type B double wall vent pipe is recommended for the vent
connector. Single wall vent connectors should not be used
unless both of the following condition are true:
a) Except for a basement, the boiler is not installed in an
unheated space.
b) The total horizontal portion of the vent connector, not
including elbows is less than 5 feet in length.
2. Outside chimneys (i.e. chimneys exposed to the outdoors
below the roof line) should not be use unless they are:
a) enclosed in a chase, or
For boilers for connection to gas vents or chimneys, vent installations shell be in
accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI
Z223.1lastest revision and applicable provisions of the local building codes.
FIG. 7
BYPASS PIPING - CIRCULATOR ON SUPPLY
FIG. 8
BYPASS PIPING - CIRCULATOR ON RETURN
BYPASS PIPING REQUIRED FOR HIGH MASS (LARGE WATER CONTENT) SYSTEMS
b) lined with type B vent pipe, or listed flexible vent liner, or
other certified chimney lining system.
3. Where possible it is recommended to common vent the
boiler and water heater.
4. For multiple boiler installations, consult the boiler
manufacturer for venting recommendations.
CONNECTING THE VENT DAMPER AND VENT
CONNECTOR
Refer to Fig. 1 the size and location of the vent (flue opening).
IMPORTANT - The damper blade on the furnished vent
damper has a 1/2 square inch hole (approximately 3/4
diameter). On boilers equipped with standing pilot, the hole
must be left open. On boilers equipped with intermittent ignition,
the hole should be plugged by using the plug supplied with
the vent damper.
1. Position furnished vent damper on top of flue outlet collar.
Fasten damper securely to flue outlet collar with sheet
metal screws. Make sure damper blade has clearance to
operate inside of diverter.
As An Option (U.S.A. Only)
The damper may be installed in any horizontal or vertical
position, closer to the flue outlet collar preferred. Follow
the diagrams - Figures 9, 10 and 11.
6
2. Install the vent damper to service only the single boiler for
which it is intended. The damper position indicator shall be
in a visible location following installation. Locate the damper
so that it is accessible for servicing.
3. The damper must be in the open position when appliance
main burners are operating.
4. The boiler is equipped with a factory wired harness that
plugs into the vent damper.
5. Slope pipe up from boiler to chimney not less than 1/4 per foot.
6. Run pipe as directly as possible with as few elbows as
possible.
7. Do not connect to fireplace flue.
8. End of vent pipe must be flush with inside face of chimney
flue. Use a sealed-in thimble for the chimney connection.
The sections of vent pipe should be fastened with sheet metal
screws to make the piping rigid. Horizontal potions of the vent
system must be supported to prevent sagging. Use stovepipe
wires every 5 to support the pipe from above. If the vent pipe
must go through a crawl space, double wall vent pipe should
be used. Where vent pipe passes through a combustible wall
or partition, use a ventilated metal thimble. The thimble should
be 4 inches larger in diameter than the vent pipe.
MINIMUM VENT PIPE CLEARANCE
Wood and other combustible materials must not be closer than
6" from any surface of single wall metal vent pipe. Listed Type
B vent pipe or other listed venting systems shall be installed
in accordance with their listing.
REMOVING EXISTING BOILER FROM
COMMON VENTING SYSTEM
When an existing boiler is removed from a common venting
system, the common venting system is likely to be too large for
proper venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected to
the common venting system placed in operation, while the
other appliances remaining connected to the common venting
system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies which
could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows
and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at
maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined above, return doors windows,
exhaust fans, fireplace dampers and any other gas-burning
appliance to their previous conditions of use.
7. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1-latest revision. When
resizing any portion of the common venting system, the
common venting system should be resized to approach the
minimum size as determined using the appropriate tables
in Part 11 in the National Fuel Gas Code, ANSI Z223.1-
latest revision.
For boilers for connection to gas vents or chimneys, vent
installations shall be in accordance with Part 7, Venting
of Equipment, of the National Fuel Gas Code, ANSI Z223.1-
latest revision and applicable provisions of the local
building codes.
Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of mechanical
draft systems operating under positive pressure.
7
Vent Damper Operation
For safe, efficient operation, the vent damper and all flue
product carrying areas of the appliance must be checked
annually by you, with particular attention given to deterioration
from corrosion or other sources. If you see corrosion or other
deterioration, contact your heating contractor for repairs.
Check vent damper operation as follows:
1. When the boiler is off, check that the vent damper positions
indicator points to the closed position, Fig. 11.
2. Turn the thermostat or controller up to call for heat and
check the vent damper indicator points to the open
position, Fig. 11.
3. Turn the thermostat or controller down again and check
that the damper position indicator returns to the closed
position.
MANUAL OPERATION OF THE VENT DAMPER
The vent damper may be placed in the open position to permit
burner operation by using the HOLD DAMPER OPEN switch,
located on the damper controller. The thermostat will control
the burner firing as before, while the damper will remain open.
DO NOT turn damper open manually or motor damage will
result. Set switch to AUTOMATIC OPERATION to close
vent damper during burner off cycle.
8
For further information, and for a vent damper troubleshooting
guide, refer to the manual that was packaged with the vent
damper.
The vent damper must be inspected at least once a year
by a trained, experienced service technician. The name
of the person who originally installed your vent damper
is shown on the installation label.
FIG. 9 FIG. 10
TYPICAL INSTALLATION FOR THE VENT DAMPER
NOTE CAUTION AND FOOTNOTES
1. Install the vent damper to service only the single appliance for
which it is intended. If improperly installed, a hazardous condition,
such as an explosion or carbon monoxide poisoning, could result.
2. Do not install the vent damper on vent pipe curve.
3. Do not run wires near high temperature surfaces. Use stand-off
brackets if necessary.
FIG. 11
VENT DAMPER POSITION INDICATOR
CHECK GAS SUPPLY
The gas pipe to your boiler must be the correct size for the
length of the run and for the total BTU per hour input of all gas
utilization equipment connected to it. See Fig. 12 for the proper
size. Be sure your gas line complies with local codes and gas
company requirements.
The boiler and its individual shutoff valve must be disconnected
from the gas supply piping system during any pressure testing
of that system at test pressures in excess of 1/2 psig (3.5 kPa).
The boiler must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 psig (3.5 kPa).
CONNECTING THE GAS PIPING
Refer to Fig. 13 for the general layout at the boiler. It shows
the basic fittings you will need. The gas line enters the boiler
from the right side.
The following rules apply:
1. Use only those piping materials and joining methods listed
as acceptable by the authority having jurisdiction, or in
the absence of such requirements, by the National Fuel
Gas Code, ANSI 2223.1-latest revision. In Canada, follow
the CAN/CGA B149.1 and .2 Installation Codes for Gas
Burning Appliances and Equipment.
2. Use pipe joint compound suitable for LP gas on male
threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection to
the gas valve to keep it from turning.
6. Install a manual shut-off valve in vertical pipe about 5
feet above floor.
7. Tighten all joints securely.
8. Propane gas connections should only be made by a
licensed propane installer.
9. Two-stage regulation should be used by the propane
installer.
10. Propane gas piping should be checked out by the
propane installer.
CHECKING THE GAS PIPING
Upon completion of piping, check immediately for gas leaks.
Open the manual shut-off valve. Test for leaks by applying
soap suds (or a liquid detergent) to each joint. Bubbles
forming indicate a leak. CORRECT EVEN THE SMALLEST
LEAK AT ONCE.
WARNING
Never use a match or open flame to test for leaks.
Gas Supply Piping
FIG. 12 - GAS PIPE SIZES
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The lenght of pipe or tubing should be measured from the
gas meter or propane second stage regulator.
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9
Electrical Wiring
All electrical work must conform to local codes as well as the
National Electrical Code, ANSI/NFPA-70, latest revision.
ELECTRIC POWER SUPPLY
Run a separate 120 volt circuit from a separate over current
protective device in the electrical service entrance panel. This
should be a 15 ampere circuit. Locate a shut-off switch at the
boiler. It must be turned off during any maintenance. Connect
120 volt power supply to aquastat terminals L1 (HOT) and L2.
The boiler, when installed, must be electrically grounded in
accordance with the requirements of the authority having ju-
risdiction or, in the absence of such requirements, with the
National Electrical Code, ANSI/NFPA No. 70-latest revision.
Run a 14 gauge or heavier copper wire from the boiler to a
grounded connection in the service panel or a properly driven
and electrically grounded ground rod.
WARNING
Turn off electric power at fuse box before making any line
voltage connections. Follow local electrical codes.
INSTALL YOUR THERMOSTAT
The thermostat location has an important effect on the
operation of your boiler system. BE SURE TO FOLLOW THE
INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT
Locate the thermostat about five feet above the floor on an
inside wall. It may be mounted directly on the wall or on
a vertically mounted outlet box. It should be sensing average
room temperature, so avoid the following:
DEAD SPOTS:
Behind doors
Corners and alcoves
HOT SPOTS:
Concealed pipes
Fireplace
TV sets
Radios
Lamps
Direct sunlight
Kitchens
COLD SPOTS:
Concealed pipes or ducts
Stairwells - drafts
Doors drafts
Unheated rooms on other side of wall
Set heat anticipator at .2 amps. 24 volt thermostat connects
to aquastat terminals T and TV.
VENT DAMPER WIRING
The boiler is equipped with a factory wired harness with 4 pin
molex plug, that plugs into a 4 pin molex receptacle inside the
vent damper operator.
The vent damper must be connected for the boiler to
operate.
Wiring diagrams follow for the various different models.
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
10
WIRING DIAGRAMS FOR HOT WATER BOILERS
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,
IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR ITS EQUIVALENT.
11
INTERMITTENT IGNITION
WIRING DIAGRAMS FOR HOT WATER BOILERS
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,
IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR ITS EQUIVALENT.
12
STANDING PILOT
Equipment and Optional Accessories - What They Do
RELIEF VALVE
You must have a relief valve on your boiler. Water expands
as it is heated. If there is no place for the water to expand into,
water pressure will build up inside the boiler and system.
Should this happen, the relief valve will automatically open at
a predetermined pressure. This will relieve the strain on the
boiler and system. Run a pipe from the relief valve outlet (pipe
must be same size as outlet and the open end must not be
threaded) to an open drain, tub or sink, or other suitable
drainage point not subject to freezing. Failure to do so may
cause water damage or injury should relief valve release.
EXPANSION TANK
In a properly assembled system, the expanding water flows
into a expansion tank. This tank should be of the correct size.
The tank is filled with air. As the water expands it compresses
the air in the tank to form an air pressure cushion. This spring-
like cushion serves to maintain correct operating water
pressure regardless of water temperature. This assures a full
measure of a water, even in the highest radiation unit of the
system. It also prevents blowing off of the relief valve. The air
in the tank in the beginning (with system filled with cold water)
is sufficient for proper operation. The tank also serves as a
trap for excess air in the system. The air would cause gurgling
in the pipes and inefficient circulation in the radiators if left in
the system .
It is possible for a tank to become waterlogged (filled with
water). It can also become overfilled with air. This can happen
after filling the system with new water. Fittings provided on
the tank and in the line to the tank are for bleeding off excess
water or air.
When installing this tank, it is important: 1) That the tank
be higher than the boiler top. 2) That the pipe to the tank
continuously rises up to the tank (so that air can bubble
up to it).
DIAPHRAGM TYPE EXPANSION TANK
The diaphragm type expansion tank (EX-TROL) takes the
place of the conventional expansion tank. Carefully read the
instructions packed with your EX TROL tank assembly.
The EX-TROL tank comes to you with a 10-12 pounds per square
inch air charge. This is the same as the pressure produced in
the system by the automatic fill valve. When the system is first
filled, the EX TROL tank will contain little or no water.
As the water is heated its pressure increases. It expands into
the EX-TROL tank, compressing the air in the tank. This
compressed air cushion permits the water in the system to
expand as the temperature changes. The diaphragm type tank
can be mounted on the air purger fitting or at any convenient
place in the supply or return line.
AIR ELIMINATING FITTING (AIR PURGER)
An air purger is used to remove excess air from the system. It
is installed in the supply line. It will eliminate air from the water
before it reaches the radiators and bleed off this air.
MAIN AIR VENT FOR DOWN FLOW SYSTEMS
OR DIAPHRAGM TYPE EXPANSION TANK
Before a system is filled with water, there is air in the pipes
and radiation units. Some of it will be trapped as the system is
filled . It is possible to eliminate most of this air through the air
vent on the radiation units. A main air vent will speed and
simplify this. It should be installed on the highest point in the
supply main when all radiation is below top of boiler.
AUTOMATIC FILL VALVE
For safe, efficient operation, a hot water system must be
completely filled with water. Adding new water, when needed
can be done manually (by use of a hand valve in the water
supply line). This requires regular attention to the systems
needs. An automatic fill valve accomplishes this without
attention. It is installed in the supply line on hot water boilers
only. The valve operates through water pressure differentials.
It does not require an electrical connection.
DRAIN VALVE
This manual valve Provides a means of draining all water from
the boiler and system. It is often installed in the 3/4 tapping at
the bottom of the end boiler section. Or it can be installed in a
tee where the return line enters the boiler.
WATER TEMPERATURE CONTROL
The water temperature limit control in the relay is adjustable
and may be set as necessary. It may be set as low as 140°F,
or as high as 240°F. This depends on the type and amount of
radiation involved and weather conditions.
CIRCULATING PUMP
Every forced hot-water system requires a circulating pump. A
separate pump or zone valve is required for each zone, if you
have a two or more zone system. This pump must have the
capacity to provide the circulation required by your system.
The pump is connected into the main just ahead of the boiler.
It is also wired to the electrical system.
VENT DAMPER
This product is an automatic, motorized stack damper that
has been developed to increase the efficiency of heating
system by reducing standby losses from the heating apparatus
and the conditioned air space. The damper closes the chimney
vent when the burner is off and fully opens it when combustion
is required.
13
ROLLOUT SWITCH
(FLAME ROLLOUT SAFETY SHUTOFF)
The rollout switch is a temperature-sensitive fuse link device.
It is located on the boiler base just outside the fire box. In the
event of heat exchanger flueway blockage causing flame to
roll out of the fire box, the fuse does not change in appearance
when blown.
If the rollout switch blows, it must be replaced with an exact
replacement. Check heat exchanger flueways for blockage
when restoring system to operating condition. DO NOT operate
system without a rollout switch.
SPILL SWITCH
(BLOCKED VENT SAFETY SHUTOFF)
The spill switch is a manual reset disc thermostat with a fixed
setpoint (340° F), and normally closed contacts. It is located at the
relief opening of the integral draft diverter. In the event of chimney
or venting system blockage causing products of combustion to
spill out of the relief opening, the spill switch disc heats up and the
spill switch contacts open, shutting down the flow of gas to the
main burners by removing power to the gas valve.
In the event that the spill switch contacts open, the reset button
on the back of the switch will pop up. The spill switch must be
reset manually, after the switch has cooled off, by pushing the
reset button down. Check the venting system and chimney for
blockage when restoring the system to operating condition. DO
NOT operate the boiler without a spill switch.
Starting Your Boiler
HOW A HOT-WATER SYSTEM OPERATES
Your entire heating system (boiler, piping and radiation units) is
filled with water. As the water in the boiler is heated, it is pumped
from the top of the boiler through the supply main to the radiation
units. The cooler water in them flows back through the return
main to the boiler. This provides positive and rapid response to
the thermostat.
FILLING SYSTEM WITH WATER
Close the air vents on all radiation units. Open the valves to
these units. Make sure the boiler and expansion tank drain
cocks are closed. The air bleed screw on the tank drain fitting
should be closed. Open the valve in the line from the boiler to
the expansion tank. Open the water inlet to your boiler and
leave it open. Start with the lowest radiation unit. Open the
air vent on this unit. When all the air has escaped and water
starts to flow from the vent, close it. Go to the next radiation
unit, and repeat this process. Repeat until you have covered
WARNING
Never run water into a hot empty boiler.
14
every radiation unit in the system (ending up at the highest
unit in the system). If your units have automatic vents, this
manual venting is unnecessary but it will speed up the proper
filling of your system.
If your system is a closed expansion tank system, you may
leave it open to refill the system automatically as needed.
Check the temperature pressure gauge. Not the position of
the hand indicating pressure. This should be between 10 and
15 lbs. Any lowering of this movable hand below 10 lbs. Will
indicate loss of water due to leakage. The automatic fill valve
should compensate for this. Instructions are packages with
the valve.
For Your Safety Read Before Operating
A. Some boilers are equipped with an intermittent ignition
device which automatically lights the pilot. Do not try to
light the pilot by hand.
Some boilers are equipped with a continuous pilot and must
be manually lighted. (See lighting instructions on page 15.)
A match holder is included in the parts bag.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not use any phone
in your building.
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
Immediately call your gas supplier from a neighbors
phone. Follow the gas suppliers instructions.
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by hand,
dont try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system
and any gas control which has been under water.
Intermittent Ignition Boiler - VR8204A/VR8304M Gas Valve Operating Instructions
1. STOP! Read the safety information on page14.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot by
hand.
5. Remove lower front panel.
6. Rotate the gas control knob clockwise toOFF
7. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas, STOP!
Follow B in the safety information on page 19 If you dont
smell gas, go to next step.
8. Rotate the gas control knob counterclockwise
to ON.
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions To
Turn Off Gas To Appliance and call your service
technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
3. Push in gas control knob slightly and turn clockwise
to OFF Do not force.
15
Continuous Pilot Boiler - VR8200A/VR8300A Gas Valve Operating Instructions
1. STOP! Read the safety information on page 14.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Remove lower front panel.
5. Rotate gas control knob slightly and turn clockwise
to OFF
6. Wait five (5) minutes to clear out any gas. Then smell for
gas, including near the floor. If you smell gas, STOP! Follow
B in the safety information on page 19 If you dont smell
gas, go to next step.
7. Find pilot - follow metal tube from gas control. The pilot is
between two burner tubes as shown in Fig. 14.
8. Turn knob on gas control counterclockwise to
PILOT
9. Rotate the gas control knob counterclockwise
to PILOT Push down and hold the red reset button while
you light pilot burner with a match.
After about one minute, release reset button. Pilot should
remain lit. If it goes out, turn gas control knob clockwise
to OFF To relight, repeat steps 5-9.
If button does not pop up when released, stop and
immediately call your service technician or gas supplier.
If the pilot will not stay lit after several tries, turn the gas
control knob to OFF and call your service technician
or gas supplier.
10. After pilot remains lit when red reset button is released,
turn gas control knob counterclockwise to ON.
11. Replace lower front panel.
12. Turn on all electric power to the appliance.
13. Set thermostat to desired setting.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
3. Push in gas control knob slightly and turn clockwise
to OFF Do not force.
Operating Your Boiler
AUTOMATIC GAS VALVE
The Automatic Gas Valve opens or closes according to the
heat requirements of the thermostat and temperature limit
control. It closes if the pilot goes out. Each individual control
must be operating correctly before any gas can pass to the
burners. Any one control can hold the gas supply from burner
regardless of the demand of any other control.
SAFETY PILOT
Safety Pilot prevents the flow of gas to burner if the pilot goes
out, or will not ignite.
GAS VALVE SAFETY SHUTDOWN TEST
1. For boilers equipped with continuous pilot, with main burners
firing, disconnect the thermocouple from the gas valve. The
gas valve should immediately shut off the main burners
and the pilot.
2. For boilers equipped with intermittent ignition, with main
burners firing, disconnect the ignition cable from the
intermittent pilot control box. The gas valve should shut off
the main burners. TURN OFF ELECTRIC POWER to boiler
before reconnecting ignition cable, to prevent electric shock.
RELIGHT
The electric and gas shall be off for 5 minutes before relighting.
THERMOSTAT
Keep it set at a desired room temperature. If windows are to
be opened or heat is not needed, move thermostat pointer to
a lower setting.
NOTE
In the event of failure of any component, the system will
not operate or will go into safety lockout. The system is
completely self-checking. On every call for heat, each
component must be functioning properly to permit
operation. On safety lockout the system has to be reset by
turning the thermostat to the lowest setting for one minute,
then back to the normal setting.
Safe lighting and other performance criteria were met with
the gas manifold and control assembly provided on the boiler
when the boiler underwent tests specified in ANSI Z21.13 -
latest revision.
16
Checking and Adjusting
FIG. 14 - LIGHTING PILOT
FIG. 15 -VR8200A/VR8300A AUTOMATIC
GAS VALVE
FIG. 17
FIG. 16 -VR8204A/VR8304M AUTOMATIC
GAS VALVE
ADJUST PILOT BURNER
Pilot flame should surround 3/8" to 1/2" of the pilot sensor.
Refer to Fig. 18. If flame needs adjusting, do it as follows:
1. Remove screw cover over pilot adjusting screw.
2. Insert small screwdriver and adjust flame as needed. Turn
screw counterclockwise to increase flame, clockwise to
decrease.
3. Replace screw cover over pilot adjusting screw.
MAIN BURNER(S)
The main burners do not require primary air adjustment and
are not equipped with primary air shutters. Main burner flames
should form sharp blue inner cones in a softer blue outer
mantel, with no yellow. Puffs of air from blowing on the flame
or stamping on the floor will cause the flames to turn orange
momentarily. This is not unusual. Remain still when observing
the main burner flames. If the flame appearance is not correct,
check main burner orifices and the burner throat and flame
ports for dust and lint obstruction. It may be necessary to
remove the rollout shield to observe the main burner flames.
Replace rollout shield after observation. Refer to Figure 17.
ADJUST LIMIT CONTROLS
Instructions for each control are included with the controls.
These settings can be changed after you have had some
idea how the system works. Example: If your system does
not give quite enough heat in very cold weather, you can
raise the limit setting to 220° F Use the boiler gauge to check
your settings. Make the adjustments according to its readings.
Check thermostat operation. When set above temperature
indicated on the thermometer, boiler should ignite. Make
certain the thermostat turns off the boiler when room
temperature reaches the selected setting and starts the boiler
operating when room temperature falls a few degrees.
After setting limit control to limit setting, check to see if it
shuts off the gas supply to the burners. Turn your thermostat
up to call for heat and let your boiler run until the temperature
of the water reaches the limit setting. The gas valve should
shut off and the circulator keep running until the thermostat
is satisfied, or the water cools
enough to restart the burners
through the limit control.
Finally, set the thermostat for the
desired temperature. Special
conditions in your home and the
location of the thermostat will
govern this setting.
RECOMMENDED BOILER WATER TEMPERATURES
Type of Heating Unit Limit Control Setting
Standing Radiators...................................180º F.
Baseboard and Convector Radiators........200º F.
FIG. 18
17
Maintaining Your Boiler
BURNERS
A visual check of the pilot end main burner flames should be
made at least once each year, preferably at the beginning of
the heating season. See page 17
RELIEF VALVE
This valve should open automatically if the system pressure
exceeds the pressure rating (usually 30 psi) of the relief valve.
Should it ever fail to open under this condition, shut down your
system. Drain the system until system pressure is reduced
below the relief valve pressure rating. If valve discharge occurs,
or if valve fails to open as described above, contact an
authorized contractor or qualified service technician to replace
the relief valve and inspect the heating system to determine
the cause, as this may indicate an equipment malfunction.
This valve should be tested every month during periods of boiler
operation, and at the beginning and end of any extended non-
service period. Prior to testing, make certain discharge pipe is
properly connected to valve outlet and arranged so as to contain
and safely dispose of boiler discharge. Test at normal system
operating pressure. Hold the trip lever fully open for at least
five seconds in order to flush free any sediment that may lodge
on the valve seat. Then permit the valve to snap shut.
EXPANSION TANK
As previously noted, this tank may become waterlogged, or
may receive an excess of air. Frequent automatic opening of
the relief valve indicates water logging. A high boiler
temperature accompanied by unusually low radiation unit
temperature (and knocking) indicates excess air in tank.
To correct either condition, close the valve between the boiler
and the tank. Drain the tank until it is empty. Check all the tank
plugs and fittings. Tighten as necessary. Open the valve
between the boiler and tank. Water will rise to the normal height
in the tank if you have an automatic fill valve (otherwise,
manually refill the system).
BOILER FLUE PASSAGES
Under normal operating conditions, with the burners properly
adjusted, it should not be necessary to clean the boiler flue
gas passages. However, to assure trouble-free operation, we
recommend that you have the flue passages, burner
18
adjustment, and operation of the controls checked once each
year by a competent Service Technician.
Before the start of each season (or whenever system has been
shut down for some time) recheck the whole system for leaks
... and recheck the boiler and vent pipe for leaks. Replace or
patch any boiler seals that are faulty.
VENT PIPE
The venting of this unit is very important and the piping should
be checked at least once a season. If the vent piping shows
any sign of leaking, replace it immediately.
WATER SYSTEM
If system is to remain out of service during freezing weather,
always drain it completely (water left in to freeze will crack the
pipes and/or boiler).
CLEANING YOUR BOILER AND BURNERS
Flue passages between sections should be examined yearly
and cleaned if necessary. To clean, remove burners, pilot, and
vent pipe, Remove top and front jacket panels. Remove the
two screws attaching the intermediate front panel to the left
and right side jacket panels. Remove the draft diverter and
intermediate front panel as a unit. Carefully remove the cerafelt
gasket strips. Clean passageways between sections with a
flexible handle wire brush. Remove dirt from bottom of boiler
and from between sections by vacuuming. Make sure all flame
ports in burners are open and clear. Shake out or blow out all
loose dirt in burners. Reseal seams between adjacent sections
as necessary with 400
°
F RTV silicone sealant. Reassemble
all parts. Be sure to check tightness of pilot connections and
condition of burner flames after reassembly (see Figures 17
and 18). Be sure vent pipe connections to chimney are secure
and no obstructions are present.
CIRCULATOR PUMP ISOLATION VALVES
The isolation valves in the circulator pump flanges should be
operated manually once or twice per year to prevent the valves
from becoming stuck in the open position Rotate the valves
from the open position to the closed position and back to the
open position.
Service Hints
You may avoid inconvenience and service calls by checking these points before you call for service.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
1. Do Not try to light any appliance.
2. Do not touch any electric switch, do not use the phone.
3. Leave the building immediately, then call your gas supplier.
4. If you cannot reach the gas supplier, call the fire department.
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.
Possible Cause What to do
Thermostat is not set correctly Reset thermostat above room temperature
Burner is not operating properly Check flame. If it is yellow, the burner is not getting enough air.
Or, if flame is blue and noisy and seems to lift off the burner, the
burner is getting too mush air. Contact your service technician.
No electric power to boiler Check over current protection. Check to be sure electric power
supply circuit is ON.
Controls out of adjustment Reset according to instructions.
Radiators not heating Open radiator vents to excess air. Check flow control valve (if
used). It may be in closed position.
Circulating pump not running Check over current protection. Check relay operation.
Poor electrical contact Check all control terminals and wire joints.
Rollout switch blown Have your service technician check heat exchanged for blockage.
Replace rollout switch with exact replacement.
Spill switch blown Have your service technician check venting system and chimney
for blockage, or down draft condition. Reset spill switch.
Vent damper not operating Consult troubleshooting guide in Effikal manual, packaged with
vent damper.
Possible Cause What to do
Gas input amount is incorrect Contact your service technician.
Possible Cause What to do
Dirt on seat Open valve manually. Allow water to run and clear valve seat.
Water logged expansion tank Drain tank, see instructions.
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
IF BURNER IS NOISY . . .
RELIEF VAVLE LEAKING . . .
19
Repair Parts
GAS FIRED HOT WATER BOILERS
IMPORTANT
READ THESE INSTRUCTIONS BEFORE ORDERING
All parts are listed in the following Parts List may be
ordered through your nearest supplier.
When ordering parts, first obtain the Model Number from the
data plate on your boiler, than determine the Part No. (not
the Key No.) and the Description of each part from the
following illustrations and list. Be sure to give us all this
information:
The Part No. The Part Description The Boiler Model No.
20
-$&.(76(&7,21$1'%$6(3$576
7+,6,6$5(3$,53$576/,67127$3$&.$*,1*/,67
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Dunkirk WPSB SERIES II Installation & Operation Manual
- Category
- Water heaters & boilers
- Type
- Installation & Operation Manual
- This manual is also suitable for
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